Coating composition and process of producing the same



Patented June 1, 1943 I COATING COMPOSITION AND PROCESS OF rnonnonva TnE SAME Francis J. Llcata, New York, N. Y.,-asslgnor to National Oil Products Company, Harrison, N. J.,. a corporation of New Jersey N Drawing. Substituted for abandoned applicai011 Serial N0. 195,120, March 10, 1938. This application January 17, 1939', Serial No. 251,311

11 Claims.

such, for example, as the normally solid water-insoluble soaps of the higher fatty or similar acids.

The mode of incorporating fiatting agents, such as aluminum stearate, zinc stearate, zinc palmitate, calcium stearate, aluminum palmitate, etc. into varnishes and lacquers according to prior practices has been to suspend fine particles of these soaps in a suitable solvent vehicle by grinding and adding the resulting suspension to the varnish or lacquer. In view of the low solubility of the soaps in the solvents, actual suspension of the particles in the solvent is obtained rather than a solution of colloidal mixture. In some instances the soaps have been suspended in the lacquer or varnish by grinding directly therewith. During the grinding operation, which is usually carried out in a pebble, stone, iron or like mill, considerable heat is developed which tends to convert the solid soap into a gel, thus rendering the product useless as far as flatting is concerned. Such gelation is particularly troublesome during the summer months when low temperature control is difficult.

The grinding operation, which usually extends over a period of several hours, offers another serious difficulty in obtaining a uniform and proper soap particle size. A particle size within certain limits is essential to ensure satisfactory fiatting in the final coating composition. If the grinding is arrested too early, coarse particles are obtained which yield gritty films and loss of diffusing power per unit weight of soap used. On the other hand, particles ground too finely gel readily and reflect too much light, thus destroying the flatting effects. It is, therefore, apparent that the grinding method is entirely empirical, diflicult to control and very costly due to the equipment necessary and power consumed in operating such equipment.

The general object of the invention is to obviate the foregoing and other disadvantages. v

A specific object of the invention is to provide a coating composition of the varnish or lacquer type containing a solid flatting agent of uniform and optimum particle size.

Another specific object of the inventionis to provide a process of dispersing a solid flatting agent in a varnish or lacquer type composition without the aid of grinding.

A further object of the invention is to provide a process of dispersing in a varnish or lacquer type composition optimum and uniform sized particles of a flatting agent. Other objects of theinvention will in part be obvious and will in part appear hereinafter.

According to the invention the process comprises precipitating a water-insoluble soapof a saturated higher fatty acid in a varnish, lacquer on like coating composition. More specifically, the process comprises adding a relatively concentrated solution of a. water-insoluble soap of a saturated higher fatty acid in a non-polar solvent to a varnish or lacquer type composition containing polar compounds and/or polar solvent or vehicle, whereby the soap is precipitated in situ within the composition. The invention further includes the composition thus obtained which is characterized by having optimum and uniform sized soap particles dispersed therein which provide an ideal fiatting effect on deposition of the varnish or lacquer.

The invention accordingly comprises the several steps and the relation of one ormore of such steps with respect'to each of the others, and the composition possessing the features, properties and the relation of constituents, which are-exemplified in the following detailed disclosure, and the scope of the invention will be indicated. in the claims.

It has now been discovered that uniform and optimum sized soap particles may be precipitated within a varnish or lacquer type composition by incorporating a relatively concentrated solution of a water-insoluble soap of a saturated higher fatty acid in a non-polar solvent into a lacquer or varnish containing a polar compound and/or a polar solvent or vehicle. Ordinarily, the nonpolar solvents are capable of only dissolving small amounts of the-water-insoluble soaps of the saturated higher fatty acids ('1. e. usually not more than 1% to 3%) and still remain fluid without forming a gel at roomtemperature. While a fluid soap solution is practically necessary in carrying out the process of. the invention,- the ordinary soap-solvent solutions are far vtoo dilute to use inasmuch as the proportion of the non-polar solvent introduced into the lacquer or vanish would be prohibitive in order to precipitate the desired. quantity of soap therein. Use should, therefore, be made of a relatively concentrated solution which can be prepared by the use of a fiuidifying agent of the type disclosed and claimed in copending application, Serial No. 117,0l8filed December 21,1936. According to this application, relatively concentrated water-insoluble soap solutions in non-polar solvents may be produced by including in the composition mahogany soaps.

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By theiiflse'cg mgh' soapslmwx ,7 p 1v tions colitainmg f m to 55%"0T flk 4hsoluble soaps may be obtained. While the use of mahogany soaps is preferred, other fluidlfyffi'g" agents may be used, such; i (triethanolamine partlcularly) of 6:1 h agents which display fluldlfylng proper ice. I j The non-polar solventsalibgl solving the soaps include 1 1 I which contain none of the so-called active R0 18; i gg y 1 /2 gallons of the such as. hyd xyl. ester. amels-g1. a Parts by weight xy n cont inin other 3011mm 3; 3o non-polar solvents recommei'iziedwndmeQll a, 1- -s'l a?" 5 ii. 'fo gallons of a lacquer o! h composltloni 53/; sec.) pounds .gallons 2 do 3 -do 2 following their halogenated, alhlated and/or i HRQ HWWIEHPQWIFMWQH leum spirits, decallng-tatniinfiimal wage; is

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mswnamemmm M11311 music ans maimed mufimom zmmmmmsm r flaifliziyln'g J agentinsimcre reamy iflre a suprior wmafiotithe fimcr m The foregoing process is adapted ior practice or 40 theWorlaoguer magm -mum kt? wedded. -,=anavvr po ir saunas ,stearateisokutinmigzmmtgflkfinfl'ltmand 3 ml] re prlriciMrfmuuWm iellflodeqlem# amoimtfi iatstriegmflihez savesmmmmsi oemw nonmnmpr zbmmch ln she mm eamrmecipitatbrtiim 4911mm :aenprwse'mmqsmmzw 545 stearate; s:- fiedieflmu or dispersed in polar solvents or vehlclemiz sauh as n 'egaywsqprom anyu or a ,e e r, be 1 as m Hand d k amber Co go esin smash ii mc ntgatedshenalic minfii a 1w v,

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i v any ide diice thfleslred degree 01 subdued lustre or fiat effect. Generally th soap solution (based on 30% soap content) may be added in amounts ranging from 1% to 25% or more. It is obvious that the concentration .of the soap solution may be varied, an operable range being about to 50% or more. The concentration of the soap solution should be selected according to the particular composition to be treated. In those cases where the coating composition contains a solvent or vehicle of the same type as the soap solution, the concentration of the latter maybe raised to prevent excess solvent in the final composition. Likewise, a lower concentration may be employed where the original composition is deficient in solvent. While the invention is particularly directed to transparent or substantially transparent lacquers or. varnishes, certain coloring agents may be included to produce varied effects. In lieu of adding the soap solution to the varnish or lacquer directly, it may be added to any on or more of their usual ingredients. For example, the soap solution may be added to a polar solvent beforehand, whereby precipitation is effected and the resulting product added to the varnish or lacquer.

The mahogany soaps included in the soap solution as a fiuidifying agent will also function as a plasticizer for the resulting composition. While the main purpose of the water-insoluble soap is to impart a fiatting effect to the composition, it will also serv as a waterproofing agent therefor. It is also to be understood that any suitable mixture of water-insoluble soaps may be employed.

This application is a substitute for application Serial No. 195,120, filed March 10, 1938.

Since certain changes in carrying out the above process and certain modifications in the composition which embody the invention may be made without departing from its scope, it is intended that all matter contained in'the above description shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language might be said to fall therebetween; and that they are intended to be inclusive in scope and not exclusive, in that if desired, other materials may be added to my novel composition of matter herein claimed Without departing from the spirit of the invention. Particularly it is to be understood that in said claims, ingredients or components recited in the singular are intended to include compatible mixtures of said ingredients wherever the sense permits.

Having described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A process of incorporating a fiatting agent into a coating composition, which comprises admixing a non-polar solvent solution containing a fluidifying agent and at least 3% of a waterinsoluble soap of a saturated higher fatty acid with a composition selected from the group consisting of substantially water-free varnishes and lacquers containing an organic polar compound, whereby the soap is precipitated and dispersed Within the composition.

2. A process of incorporating a flatting agent into a coating composition, which comprises admixing a non-polar solvent solution containing a fluidifying agent and at least 3% aluminum stearate with a composition selected from the group consisting of substantially water-free varnishes and lacquers containing an organic polar compound, whereby the aluminum stearate is precipitated and dispersed within the composition.

3. A process of incorporating a flatting agent into a coating composition, which comprises admixing a non-polar solvent solution containing mahogany soaps and at least 3% aluminum stearate with a composition selected from the group consisting of substantially water-free var-- nishes and lacquers containing an organic polar compound, whereby the aluminum stearate is precipitated and dispersed within the composition.

4. A process of incorporating a fiatting agent into a coating composition, which comprises admixing with a composition selected from the group consisting of substantially water-free varnishes and lacquers containing a polar solvent, a composition comprising 3% to aluminum stearate, mahogany soaps and a non-polar solvent, whereby the aluminum stearate is precipitated and dispersed within the composition.

5. A process of incorporating a flatting agent into a lacquer, which comprises admixing a nonpolar solvent solution containing a fiuidifying agent and at least 3% of a water-insoluble soap of a saturated higher fatty acid with a substantially water-free cellulose ester lacquer, whereby the soap is precipitated and dispersed throughout the lacquer.

6. A process of incorporating a flatting agent into a lacquer, which comprises admixing a nonpolar solvent solution containing mahogany soaps and at least 3% aluminum stearate with a substantially water-free cellulose ester lacquer, whereby the aluminum stearate is precipitated and dispersed throughout the lacquer.

'7. A process of incorporating a flatting agent into a varnish, which comprises admixing a nonpolar solvent solution containing a fluidifying agent and at least 3% of a Water-insoluble soap of a saturated higher fatty acid with a substantially water-free resinous varnish containing a I polar compound, whereby the soap is precipitated and dispersed throughout the varnish.

8. A process of incorporating a flatting agent into a varnish, which comprises admixing a nonpolar solvent solution containing mahogany soaps and at least 3% aluminum stearate with a substantially water-free resinous varnish containing a polar compound, whereby the aluminum stearate is precipitated and dispersed throughout the varnish.

9. A coating composition selected from the group consisting of substantially water-free varnishes and lacquers containing aluminum stearate precipitated in situ therein from a nonpolar solvent solution thereof, said soap imparting a flatting efiect to the composition.

10. A fiat type cellulose ester lacquer having aluminum stearate precipitated in situ therein from a non-polar solvent solution thereof, said lacquer being substantially water-free.

11. A fiat type resinous varnish having aluminum stearate precipitated in situ therein from a non-polar solvent solution thereof, said varnish being substantially water-free.

FRANCIS J. LICATA. 

